Seat cushion using vertically lapped fiber

ABSTRACT

A seat cushion is disclosed that can be easily attached to, and removed from, a chair or seat utilizing a mesh seat bottom. The removable seat cushion includes a collection of downwardly extending engagement members that engage the mesh upon insertion through voids in the mesh. In certain applications, the seat cushion is formed from a vertically lapped fibrous batt.

CROSS REFERENCES TO RELATED APPLICATIONS

This application claims priority upon U.S. provisional application Ser.No. 60/738,074 filed Nov. 19, 2005.

BACKGROUND OF THE INVENTION

In the office landscape environment, much of the furniture, includingchairs and seating units utilize a mesh or woven fabric supportingmember as a seat bottom. While providing good aesthetic properties, meshseating bottoms frequently suffer from limited comfort and cushioningqualities. Accordingly, there is a need for an improved seating systemthat can be readily used with such mesh seating bottoms.

Removable seat cushions are known in the art. These cushions typicallyinclude a padded member that can be placed on a seating surface.Although satisfactory in many regards, conventional seat cushionsgenerally utilize a flat base member which does not conform to contouredseat bottoms used in many of today's office furniture. Accordingly,there is a need for a removable seat cushion that is readily adapted foruse with a contoured seat.

Provisions are known in the art for attaching a seat or seat cushion toan underlying seat or chair. Such provisions include straps that areattached to one another such as by buckling, or tie downs that aresecured to the underlying seat. It is often tedious and difficult to tieor otherwise secure such tie downs or snaps, and equally difficult torelease them after use, in order to remove the seat cushion.Accordingly, there is a need for an improved strategy by which aremovable seat cushion can readily be secured to an underlying seat orsupporting surface.

Furthermore, fire retardancy is an increasing concern for officefurniture. As efforts are underway by suppliers of office furnituresystems and seating units to increase the degree of fire retardancy ofsuch products, it would be desirable to also impart fire retardantproperties to components used in conjunction with such products.

BRIEF DESCRIPTION OF THE INVENTION

The present invention achieves all of the foregoing objectives andprovides, in a first aspect, a furniture component comprising a framemember and a cushion member disposed on the frame member. The cushionmember has first and second oppositely directed faces. The cushionmember includes a region of vertically lapped fibers. The region extendsgenerally across a face of the cushion member. At least a majority ofthe fibers in the region extend in a direction generally transverse to aface of the cushion member.

In another aspect, the present invention provides a removable seatcushion adapted for use with a chair having a mesh seat defining acollection of small apertures extending through the thickness of theseat. The seat cushion comprises a cushion member defining an uppersurface and an oppositely directed bottom surface. The cushion memberincludes a region of a nonwoven mat of vertically lapped fibers. Theseat cushion also comprises a frame component generally extending alongat least one of the bottom surface of the cushion member, and the outerperiphery of the cushion member. The seat cushion also comprises acollection of downwardly extending engagement members affixed to theframe component and adapted to releasably engage the mesh seat of thechair.

In yet another aspect, the present invention provides a method offorming a seat cushion having a region of vertically lapped fibers. Themethod comprises forming a frame component by placing a thin layer of amoldable polymeric material into a first mold and heating to therebyform the frame. The method also comprises positioning the frame in asecond mold in conjunction with a collection of fasteners adapted to bemolded to or otherwise affixed to the frame, and a layer of a nonwovenbatt of vertically lapped fibers, and heating the frame, fasteners, andlayer to thereby form an intermediate assembly. The method alsocomprises positioning the intermediate assembly into a third mold inconjunction with a layer of a covering material in position to cover aface of the intermediate assembly, and heating the intermediate assemblyand covering material to thereby form the seat cushion.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention will be described in detail with several preferredembodiments and illustrated, merely by way of example and not withintent to limit the scope thereof, in the accompanying drawings.

FIG. 1 is a perspective view of a typical chair utilizing a contouredmesh seat bottom.

FIG. 1A is a detailed view of a mesh material used in the seat portionof the chair shown in FIG. 1.

FIG. 2 is a view illustrating placement of a preferred embodiment seatcushion on the chair of FIG. 1.

FIG. 3 is an exploded view illustrating components of a preferredembodiment seat cushion.

FIG. 4 is a cross-sectional view of a cushion member of the seat cushionshown in FIG. 3 taken along line 4-4.

FIG. 5 is a cross-sectional view of a frame component taken across line5-5 in FIG. 3, illustrating a preferred embodiment engagement member.

FIG. 6 is a view of another preferred embodiment engagement member usedin the seat cushion described herein.

FIG. 7 is a view of another preferred embodiment engagement member.

FIG. 8 illustrates another preferred embodiment engagement member.

FIG. 9 illustrates yet another preferred embodiment engagement member.

FIG. 10 illustrates another preferred embodiment engagement member.

FIG. 11 illustrates yet another preferred embodiment engagement member.

FIG. 12 illustrates yet another preferred embodiment engagement member.

FIG. 13 illustrates another preferred embodiment engagement member.

FIG. 14 illustrates yet another preferred embodiment engagement member.

FIG. 15 illustrates a retainer component of another preferred embodimentseat assembly and a molding tool used to form the retainer.

FIG. 16 illustrates an intermediate assembly used in the preferred seatassembly referenced in FIG. 15, and a molding tool used to form theassembly.

FIG. 17 illustrates the preferred seat assembly referenced in FIGS. 15and 16, and a molding tool used to form the final seat assembly.

FIG. 18 illustrates the various stages of manufacturing the preferredseat assembly and the molding tools used therefor.

FIG. 19 is a schematic cross section of a preferred embodiment seatcushion utilizing a region of a vertically lapped fibrous batt.

FIG. 20 is a schematic cross section of a preferred embodiment arm padusing a region of a vertically lapped fibrous batt.

FIG. 21 is a schematic cross section of another preferred embodiment armpad, utilizing a major proportion of a vertically lapped fiber.

FIG. 22 is a side elevational view of a first side of a preferredembodiment seat assembly.

FIG. 23 is a view of a second side of the seat assembly depicted in FIG.22.

FIG. 24 is a view of a third side, opposite the first side, of the seatassembly depicted in FIG. 22.

FIG. 25 is a view of a fourth side, opposite the second side, of theseat assembly depicted in FIG. 22.

FIG. 26 is a view of the top of the seat assembly depicted in FIG. 22.

FIG. 27 is a view of the underside of the seat assembly depicted in FIG.22.

FIG. 28 is a perspective view of the seat assembly depicted in FIG. 22.

FIG. 29 is a side elevational view of a first side of another preferredembodiment seat assembly.

FIG. 30 is a side elevational view of a second side of the seat assemblydepicted in FIG. 29.

FIG. 31 is a side elevational view of a third side, opposite the firstside, of the seat assembly depicted in FIG. 29.

FIG. 32 is a side elevational view of a fourth side, opposite the secondside, of the seat assembly depicted in FIG. 29.

FIG. 33 is a view of the top of the seat assembly depicted in FIG. 29.

FIG. 34 is a view of the underside of the seat assembly depicted in FIG.29.

FIG. 35 is a perspective view of the seat assembly depicted in FIG. 29.

FIG. 36 is a side elevational view of a first side of another preferredembodiment seat assembly.

FIG. 37 is a side elevational view of a second side of the seat assemblydepicted in FIG. 36.

FIG. 38 is a side elevational view of a third side, opposite the firstside, of the seat assembly depicted in FIG. 36.

FIG. 39 is a side elevational view of a fourth side, opposite the secondside, of the seat assembly depicted in FIG. 36.

FIG. 40 is a view of the top of the seat assembly depicted in FIG. 36.

FIG. 41 is a view of the underside of the seat assembly depicted in FIG.36.

FIG. 42 is a perspective view of the seat assembly depicted in FIG. 36.

FIGS. 43 and 44 are views of a set of ring components arranged in apreferred pattern, prior to molding.

FIG. 45 is a side view of a preferred ring component after molding.

FIGS. 46 and 47 are views of the set of ring components depicted inFIGS. 43 and 44.

FIG. 48 is a view of the sides of the ring components shown in FIGS.43-44 and 46-47.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The preferred embodiments relate to a seat cushion which utilizes one ormore layers of a vertically lapped fiber. Such seat cushions alsoinclude a frame assembly and preferably, a collection of downwardlyextending engagement members. The collection of engagement members aresized and shaped so as to releasably engage a mesh chair seat, as isfrequently used in chairs designed for office and home environments.

FIG. 1 illustrates a typical chair 100 with which the preferredembodiment seat cushions are used in conjunction. The chair 100typically comprises a seat back 110 and seat bottom 120 andcorresponding seat bottom frame 128 positionably coupled together by aframe assembly 115 extending therebetween. The chair 100 also comprisesfirst and second arm members 130 and 132 engaged with the frame assembly115 and/or the seat back 110 by support members 131 and 133,respectively. The sub-assembly of the seat back 110, seat bottom 120,frame assembly 115, and arms 130 and 132 is generally disposed andsupported on a pedestal 140 extending between the frame assembly 115 anda base 150. The base 150 can be in a variety of different forms andarrangements, however, it is typical to utilize a plurality of outwardlyextending support members each having a caster 160 or other rollingmember disposed on their underside.

The seat bottom 120 of the chair 100 preferably utilizes a relativelythin supporting member such as a mesh or a woven fabric. The supportingmember or mesh extends across the seat bottom frame 128 that imparts acontoured configuration to the mesh spanning that frame. The term “mesh”as used herein refers to any thin planar member having a plurality ofsmall voids, apertures, holes, or openings extending through thethickness of the member. In the representative example shown in FIG. 1A,the mesh used in the seat bottom 120 includes a collection of parallelextending fibers or strands 122 and a second set of parallel extendingfibers or strands 124 extending at right angles with the first set offibers or strands 122. The sets of fibers or strands, i.e. 122 and 124,can be bonded to each other at their locations of intersection oncontact, or remain unbonded. The resulting voids 125 defined at theintersections of these spaced fibers or strands can be in a variety ofdifferent shapes and sizes. However, it is typical for the shape of avoid 125 to be square or rectangular. The size of the void, or ratherspan or dimension of a void, is generally somewhat variable. The spanmay be significantly increased if the sets of fibers or strands such as122 and 124 are not bonded to one another and forces or stresses urgethe fibers apart from one another.

FIG. 2 illustrates positioning and placement of a preferred embodimentseat cushion 200 onto the chair 100 depicted in FIG. 1. The seat cushion200 generally includes a cushion member 210 defining an upper surface214 and an oppositely directed bottom surface 212. The seat cushion 200also comprises a frame component 220 generally extending along theunderside 212 and/or about the outer periphery of the cushion member210. The frame component 220 includes a collection of downwardlyextending engagement members 230 described in greater detail herein. Thegeometry and configuration of the underside of the seat cushion 200 ispreferably shaped to conform with the geometry and configuration of theseat bottom 120 of the chair 100. However, the present inventionincludes seat cushions that do not exhibit such matching characteristicssince the seat cushion 200 is preferably flexible and can be flexed orotherwise deformed to match the shape or contour of the seat bottom 120.

FIG. 3 is an exploded view of a preferred embodiment seat cushion 200.The seat cushion 200 includes a cushion member 210 having the notedupper surface 214 and bottom surface 212. The upper surface 214 andbottom surface 212 are generally separated by a laterally extendingperimeter 216 extending around the perimeter of the cushion member 210.The seat cushion 200 also comprises a frame component 220. The framecomponent defines a top surface 224 and an oppositely directed undersurface 222. Upon engagement of the cushion member 210 to the framecomponent 220, the topside 224 of the frame component 220 is preferablyin contact and immediately adjacent to the bottom surface 212 of thecushion member 210. The frame member also includes a plurality ofdownwardly extending engagement members 230, described in greater detailherein.

FIG. 4 is a cross-section of the cushion member 210 taken along line 4-4in FIG. 3. The cushion member 210 includes a deformable interior member217 generally surrounded by an optional protective covering 211.

The interior member 217 of the cushion member 210 is a unified ormonolithic member and preferably includes a matrix fiber, a cellulosefiber, and a binder polymer that serves as an adhesive to bind thecomponents together. The interior member 217 may also include variousfillers and additional materials as well. The various components areassembled and melt-bonded together to form a finished member.

The matrix fiber for use in the interior member provides structure andstrength characteristics to the cushion member. The interior memberprovides the structure to form the cushion member into the desiredshape. The matrix fiber is preferably a high melting point polyester,polyethylene terephthalate (PET), or another thermoplastic. Anythermoplastic used as the matrix fiber should preferably have a meltingpoint higher than the temperatures used in the molding of the interiormember 217 as described below. That is, while it is acceptable for thematrix fiber used in the present invention to become soft during themolding process, it should not melt to the extent of becoming a moltencomponent or losing its structure completely. More than one type ofmatrix fiber may be used in the construction of the cushion member 210.Alternately or in addition to the thermoplastic fiber, natural fiberscould be used such as sisal, jute, kenaf, coconut fiber or hemp.

The cellulose fiber of the preferred embodiment cushion member is usedto provide mass and shape to the interior member as well as contributeto its fire resistance. To increase its fire resistance, the celluloseis treated with a fire retardant in an amount necessary to render itnonflammable. Suitable fire retardants include, but are not limited to,boric acid and/or sodium polyborate. Suitable treated cellulose fiberfor use in the present invention includes NU-WOOL®), available fromNu-Wool Co., Inc. and boron cellulose available under the tradenameTHERMOLOK INCIDE from Hamilton Mfg. Inc. The cellulose fiber preferablyconstitutes from about 40 to about 70% by weight of the cushion member,more preferably 45 to 55%.

The binder polymer of the interior member of the cushion acts as anadhesive and binder to bond the matrix fiber and cellulose fibertogether and lock the fibers into position. Thus, the binder polymerwill at least partially melt during the molding process. The binderpolymer can be any recyclable fiber having this characteristic, such aspolyester, PET, polypropylene, polyethylene, nylon, PLA and acrylic.Preferably, the binder polymer is a polyester having a melting point ofabout 100° C. During the process, the binder polymer at least partiallymelts and becomes flowable, penetrating between the matrix fibers andthe cellulose fibers to bond them together. Upon cooling, the binderpolymer solidifies to form the final interior member.

In one embodiment of the present invention, the matrix fiber and thebinder polymer are provided as a single bi-component blended fiber. Inthis bi-component fiber, the two materials may be arranged in co-axialarrangement, with an inner strand of higher melting point matrix fibersurrounded by a sheath of lower melting point binder polymer. Suitablepolyester bi-component fibers for use in the present invention arecommercially available under the trade designation “PET bi-componentfiber” from various manufacturers. Various sized bi-component fibers maybe used in the present invention seat cushion or products depending onthe particular use. Although not intended to be limiting, a typicalbi-fiber suitable for use in most applications of the present inventionhas a diameter of about 5 denier or smaller. When bi-component fiber isused, a preferred seat cushion interior member according to the presentinvention will contain about 30 to about 60% by weight bi-componentfiber and about 40 to about 70% by weight cellulose. In any event, theamount should be enough such that the resultant member will pass ASTME84 flame test for building materials and UL 723 test.

Most preferably, the interior member of the cushion member comprisesfrom about 20% to about 40%, and most preferably about 30% of binderpolymer, and from about 60% to about 80%, and most preferably about 70%matrix fiber.

Upon formation into the interior member, the member has a loft of about0.300 to about 0.700, and preferably about 0.500.

The optional covering 211 of the preferred embodiment cushion member maybe a layer made from any decorative membrane, including fiber andnon-fiber materials and woven and non-woven materials. Additional fillermaterials may also be added to enhance strength or other panelcharacteristics, such materials including, but not limited to, variousthermoplastics such as polyester, co-polyester, and nylon; naturalmaterials such as sisal, hemp, cotton and flax; or other materials suchas ceramic powder, fire-retardant materials, or metal mesh. Specializedadditives may also be added to improve certain properties of thefinished cushion member, including but not limited to, pesticides,anti-microbial additives, ammonia dust inhibitors, stabilizers, andwater repellants.

The resulting cushion member such as 210, may be constructed using aconventional carding line and cross lapper in various arrangements. Forconvenience, a representative process will be described using apolyester bi-component fiber, cellulose and a finish layer only. Asstated above, however, various other processes may be used to make thecushion member and additional fibers and additives may also be combinedto produce the cushion member. The bi-component fiber is introduced on agarnett or carding machine, which straightens and parallelizes theloosened bi-component fiber to form a web of parallel, crimped fibers.As the bi-component fiber web exits the carding machine, the treatedcellulose fiber is spread out over the top of the web. Any additionaladditives, such as pesticides, may be added at this stage or prior tothe forming of the web. The resulting cellulose covered web is thendirected through a cross lapper, to build up the web into a batt and tointegrate the cellulose with the bi-component fiber. The resulting battis cut to length and then heated, in an oven to melt the outer sheath ofthe bi-component fiber (the binder polymer) and cause it to intimatelyblend the cellulose and the inner strand of the bi-component fiber (thematrix fiber). This provides a “through-bonded” batt that not only bondsthe components of the member, but also seals the surface of the battagainst leakage. Any conventional carding machine and cross lapper maybe used in this process. A suitable cross lapper is Crosslapper modelCL-OC available from Technoplants. Additionally, other known processesfor forming batts may be used, such as those disclosed in U.S. Pat. Nos.5,974,631 and 6,276,028, the disclosures of which are incorporatedherein by reference.

The batts are heated to a point where the binder polymer transitionsfrom a solid state to a liquid state. Although the temperature at whichthe batts are heated will therefore vary depending on the composition ofthe matrix fiber and binder polymer, a typical heating cycle using apolyester bi-component fiber includes heating the batts to about 150° F.to about 375° F. Some of the binder polymer fibers may liquefy whileothers remain in a transition or gel-like condition. Thus, the battbecomes soft and pliable, yet can still be handled because the matrixfiber and cellulose retain enough of the batt structure. If the battsare to be molded into specific shapes to form a finished cushion member,the batts are transferred by a conveyor from the oven to a bondingpress. If a finish layer is to be used in the manufacture of the cushionmember, it is transferred, from a fabric carousel or other dispenser tothe bonding press at this stage. The finish layer is mated and alignedwith the hot batt and the press is then closed, capturing and pressingthe finish layer to bond it to and embed it in the batt.

Regardless of whether a finish layer is used, the bonding press isclosed and the batt is pressed, between the mold halves or dies of thepress. The batt, still hot from the oven, assumes the shape of theinterior of the press. The binder polymer may further transition to amolten state at this time due to the pressure of the press. The moltenbinder polymer flows throughout the mold cavity and binds the celluloseand matrix fibers together. If a finish layer is used, the moltenmaterial is also pressed into this layer, so it becomes at leastpartially embedded in the batt.

The mold halves or dies are preferably temperature controlled below themelting temperature of the binder polymer. Thus the oven heats the battand the pressure of the closed mold in the press shapes the batt beforethe transfer of heat from the batt to the dies sets the batt in a solidstate.

As discussed above, the binder polymer preferably at least partiallymelts to become a molten material during the heating in the oven.However, it preferably remains viscous rather than free-flowing. Thus,the binder polymer will only flow throughout the mold cavity when thepress closes the mold and pressure is applied to the batt. Because ofthis, the final cushion member may have localized areas of relativelyhigher material density, and associated greater material toughness,where the added batt material was originally placed in the mold.

The cushion member may be constructed using a single batt or acombination of different batts having different compositions. Thus, amanufacturer can make cushion members having customized structures andproperties based on a user's requirement. The combining of differentbatts allows a fabricator to tailor the characteristics of the resultingcushion member by positioning strata of component materials within theresulting cushion member. For example, a second batt comprised of ablend including a filler material may be used with a first batt tointroduce and position a stratum of filler material into the resultingcushion member. The second batt may be assembled using the same processdescribed above, with an exception that fibers of a filler material areincluded in the blend. The first and second batts may be introduced toeach other before or after they are heated in the oven. Preferably, thetwo batts are introduced prior to heating, so that they may become atleast partially bonded together during heating by the melting anddiffusion of the binder polymer between the two batts.

As noted, it should be realized that a cushion member of the inventionmay be constructed with various alternative “lay-ups” of different fiberand filler layers and multiple batts prior to molding in the bondingpress. By selecting different components for use in the batt or amultiple number of batts or by changing the thickness of each batt, onemay alter the stiffness, toughness, acoustics and other characteristicsof the resulting cushion member. For example, strength and othercharacteristics may be enhanced with the use of metal or ceramic fibersadded to the batt. A rigid support structure, such as a metal mesh orfoil, may be embedded in the cushion member for additional strength byincluding the structure in the batt or web lay-up.

Structural characteristics of the cushion member may also be controlledby adjustment of the material density and the mold pressure. For a givenamount of material, a defined mold cavity volume will result in aparticular material density. With a constant mold cavity volume,increasing the amount of material in the batt will increase theresulting density in the final cushion member. A cushion member with arelatively higher material density will exhibit a greater toughness thatresists puncturing. Conversely, decreasing the amount of material in thebatt will produce a cushion member with a relatively lower materialdensity, resulting in a lighter, less tough cushion member susceptibleto puncturing and the insertion of pins and the like. Thus, for example,a cushion member of the invention can be made to be a fully tackablemember by reducing the resulting material density appropriately.

In a particularly preferred embodiment, either one or both of thecushion members and the frame component are formed from a nonwoven mator batt of vertically lapped fibers. Such batts are commerciallyavailable such as for example, from Structured Fibres, Inc., ofSaltillo, Miss. Another source of commercially available verticallylapped nonwoven fabrics, is Struto International, Inc., of KingsMountain, N.C. Batts of vertically lapped fibers are unique because theyinclude a significant proportion of fibers that extend in a verticaldirection, i.e. in a direction generally transverse to the plane of thebatt. Preferably, at least a majority proportion of the fibers in a mator batt, extend in such a vertical direction. More specifically, it ispreferred that for the fibers extending in a generally verticaldirection, i.e. approximately transverse to the plane of the mat, atleast 50% of the fiber length extends in such vertical direction. Morepreferably, at least 90% of the fiber length of such fibers extends inthis direction. And, most preferably, at least 95% of the fiber lengthof such fibers extends in such direction. It will be appreciated thatthese are aspects of the mat prior to any compression or thermoforming.Batts featuring such a fiber orientation are able to provide a firmnessgenerally not possible using a batt with a traditional horizontalorientation. Preferably, the vertically extending fibers are retained inposition, within the mat, by an effective amount of a binder polymer,such as a lower melting point polyethylene. General backgroundinformation as to manufacturing batts with significant proportions ofvertically extending fibers is found in U.S. Pat. Nos. 5,618,364 and7,011,181; both of which are hereby incorporated by reference.

As described in greater detail herein, batts of vertically lapped fibersare particularly useful in seating and arm pad applications. Verticallylapped fiber batts can be formed to provide components having thefirmness characteristics such as typically required for arm pads andcertain seating applications. Seating and arm pads can be formed fromthe batts of vertical lapped fibers. Seating and arm pad under-supportscan also be formed from the vertically lapped fibers and can be usedbetween a frame member and a covering layer.

The preferred embodiment seats, seat cushions, seating assemblies, armpads, and other like components described herein can include one or morelayers of a matt or batt of vertically lapped fibers. Generally, anytype of fiber can be used, including synthetic fibers and natural fibersand combinations thereof. A wide array of fiber sizes can be used, suchas from about 0.9 to about 300 denier, or more particularly from about 2denier to about 15 denier. The resulting web or matt weight can rangefrom about 100 g/m² to about 2000 g/m². If blends of fibers are used, aspreviously noted, thermobondable fibers can be used, such as from about10 to about 100% of the total weight of fibers in the matt.

Preferably, the batt of vertically lapped fibers comprises a particularblend of fibers as follows. From about 5% to about 95% of a first fiber,or matrix fiber, and from about 95% to about 5% of a second fiber havinga melting point less than the first fiber are used. Preferably, about60% of the first fiber and about 40% of the second fiber are utilized.These percentages are percentages of the particular fiber based upon thetotal weight of the batt. The first fiber can be in a range of sizes,such as from about 0.9 denier to about 300 denier, with 15 denier beingpreferred. The second fiber can also be in a range of sizes, such asfrom about 2 denier to about 15 denier with 4 denier being preferred.The length of the second fiber is preferably from about 1 inch to about3 inches, with 2 inches being preferred. The length of the first fiberis generally dictated by end use requirements.

The particular percentages or proportions of each of the first andsecond fibers in the batt of vertically lapped fibers can vary dependingupon the characteristics desired for the final cushion product.Generally, the greater the proportion of the second fiber, i.e. the lowmelting point fiber, the firmer the resulting cushion. Conversely, asofter cushion can be formed by using less of the second fiber. Reboundcharacteristics of the cushion can also be improved by decreasing theproportion of the second fiber.

The frame component of the preferred embodiment seat cushions ispreferably formed from the same materials as utilized for the interiormember of the cushion member of the seat cushion. Generally, thematerials for the frame component are selected, and used in suchproportions, that the frame component is relatively rigid. The framecomponent preferably comprises from about 30% to about 100%, and mostpreferably about 70% of the binder polymer, and from about 70% to about0%, and most preferably about 30% of the matrix fiber.

Although the frame component may be in a variety of different shapes,configurations, and dimensions, preferably the frame component isgenerally planar with a thickness of about 0.10 inch (about 0.25 cm) toabout 0.010 inch (about 0.025 cm) thick, and most preferably about 0.050inch (about 0.125 cm) thick.

After formation of the frame component, one or more of the engagementmembers are preferably molded thereon. Sufficient heat and pressure areutilized to bond the materials of the frame component and the engagementmembers together. Molding or attachment of the engagement members to theframe component can be performed in conjunction with affixment of theframe component to the cushion member. Optionally, the covering or coverlayer of the cushion member can then be applied. Alternately, thecovering can be applied prior to affixment of the frame component to thecushion member.

Most preferably, the molding or attachment of the plurality ofengagement members is performed concurrently with the molding andformation of the interior member of the cushion member. That is, theinterior member is formed and integrally molded on or about the framecomponent in conjunction with molding or attaching the engagementmembers to the frame component. This strategy eliminates a secondary oradditional molding operation.

The engagement members can be formed from nearly any material. Forexample, the engagement members can be formed from the same material(s)as the cushion member and/or the frame component. Alternatively, theengagement members can be formed from a similar or different moldablepolymeric material such as for example, polyethylene, polypropylene,polystyrene and the like.

FIG. 5 is a detailed partial cross-sectional view of the frame componenttaken across line 5-5 in FIG. 3. FIG. 5 illustrates a typical engagementmember 230 extending from the under surface 222 of the frame component220. The engagement member 230 detailed in FIG. 5 includes a distal tipmember 232 and a shaft 234 extending between the frame component 220 andthe distal member 232. One or more engagement flaps or projections 235may be provided along the outer -surface of the shaft 234. As describedin greater detail herein, the engagement flaps or projections releasablyengage a mesh material upon insertion through voids defined in thatmaterial. The engagement member 230 may extend through the framecomponent 220 and further be secured to the frame component 220 by ahead component 236 which lies along the upper surface 224 of the framecomponent 220.

FIGS. 6-14 illustrate additional preferred embodiment engagement membershaving various profiles. FIG. 6 illustrates a preferred embodimentengagement member 330 having a tip 332 with a shaft 334 extendingbetween the tip 332 and a corresponding frame component (not shown). Thepreferred embodiment engagement member 330 includes a plurality ofoutwardly extending projections 335 separated by a valley 336.

FIG. 7 illustrates another preferred embodiment engagement member 430.The engagement member 430 includes a tip 432 and a shaft 434 extendingbetween the tip 432 and a frame component. The shaft includes anoutwardly projecting member 435.

FIG. 8 illustrates another preferred embodiment engagement member 530.The member 530 includes a tip 532 and a relatively smooth shaftextending between the tip 532 and a corresponding frame component.

FIG. 9 illustrates another preferred embodiment engagement member 630.The member 630 includes a tip 632 and a shaft 634 extending between thetip 632 and a frame component. The preferred embodiment engagementmember 630 is characterized by one or more depressions or valleys 636defined along the shaft 634.

FIG. 10 illustrates another preferred embodiment engagement member 730.The engagement member 730 includes a tip 732 and a shaft 734 extendingbetween the tip 732 and a corresponding frame component. The engagementmember 730 includes one or more outwardly extending continuousprojections 735.

FIG. 11 illustrates another preferred embodiment engagement member 830.The member 830 includes a distal tip 832 and a shaft 834 extendingbetween a frame component and the tip 832. The engagement member 830also includes one or more noncontinuous projections 835 extendingoutward from the shaft 834 and/or tip 832.

FIG. 12 illustrates yet another preferred embodiment engagement member930. The engagement member 930 includes a distal tip 932 and a shaft 934extending between the tip 932 and a corresponding frame component. Theengagement member 930 includes one or more outwardly extendingprojections such as 935.

FIG. 13 illustrates yet another preferred embodiment engagement member1030. The engagement member 1030 includes a distal tip 1032 and a shaft1034 extending between a frame component and the distal tip 1032. Thepreferred embodiment engagement member 1030 includes a plurality ofoutwardly extending projections 1035.

FIG. 14 illustrates another preferred embodiment engagement member 1130.The engagement member 1130 includes a distal tip 1132 and a shaft 1134extending between the tip 1132 and a corresponding frame component. Thepreferred embodiment engagement member 1130 includes a projection suchas 1135.

Regardless of the specific form or profile of the engagement member, itis generally preferred that such member includes one or more outwardlyextending engagement flaps or projections such as for example 235 shownin FIG. 5. Upon placement of the preferred embodiment seat cushion upona mesh seat bottom of a chair, such as depicted in FIG. 2, one or moreof the engagement members are inserted into, and through, the meshmaterial forming the seat of the chair. Specifically, the engagementmembers extend through voids or openings defined in the mesh. Utilizinga tapered distal end member such as member 232 in FIG. 5 facilitatesalignment of the fibers, strands, or other material forming the meshwith the engagement member such that the engagement member can readilyextend within an opening defined in the mesh. As the engagement memberis displaced into the opening and past the mesh, the engagement flaps orprojections, such as 235 in FIG. 5, preferably contact and engageportions of adjacent mesh material. This action is used to secure andretain the seat cushion upon the mesh seat bottom once placed thereon.The seat cushion can be easily removed from the seat bottom by simplydisplacing the cushion away from the seat bottom. The engagement flapsor projections readily deform to allow adjacent mesh material to passby. Although the preferred embodiment seat cushion includes a collectionof engagement members having flaps or projections, the inventionincludes engagement members free of such structures, such as theengagement member 530 shown in FIG. 8.

In one embodiment, and referring to FIGS. 2-3, a thin seat cushion orpad 200 is secured over one or both of the seat and back seatingstructure. Preferably, the thin pad is a molded batt or panel material,as disclosed for example in U.S. Patent Application Publication US2004/0028958 A1 (U.S. application Ser. No. 10/463,187), PCT ApplicationPCT/US01/10262 (Publication No. WO 01/74583 A1), U.S. ProvisionalApplication No. 60/193,196, U.S. Provisional Application No. 60/389,647,U.S. application Ser. No. 09/869,418, PCT Application PCT/US00/32272 andU.S. Provisional Application No. 60/167,303, all of which are herebyincorporated herein by reference. In particular, the pad includes alayer of moldable material 217 and a finish material 211, such as afabric, secured or disposed along one side of the moldable material.

The thin pad can be formed in a three-dimensional shape to mate with andconform to the upper, body-facing surface of a seating structure,whether it be the back or seat. As previously noted, in one embodiment,the moldable material is made of a non-woven material, and can includewithout limitation thermoplastics, polyester, co-polyester,polypropylene, nylon, polyethylene, or combinations thereof. Forexample, one suitable non-woven material is available from westernNonwovens, Los Angeles, Calif. The finish, e.g. fabric, is bonded to themoldable material substrate with an adhesive, for example and withoutlimitation a powder adhesive, including for example, and withoutlimitation a co-polyester resin available from EMS-Griltech, S.C.Alternatively, the fabric is simply embedded into the moldable materialsubstrate. In certain embodiments, the overall pad preferably has athickness of 0.10 inches (0.25 cm) to about 0.75 inches (1.9 cm), or0.20 inches (0.5 cm) to about 3.0 inches (7.6 cm) and in one embodimentis about 0.25 inches (0.66 cm) when covering the back and about 0.50inches (1.3 cm) when covering the seat. The pad is relatively thin, suchthat it is flexible and can flex and conform to the underlying seatingstructure.

Referring to FIGS. 3-5, a seat pad assembly 200 is shown as including aframe or rim component 220, a pad component 217 and a fabric coveringcomponent 211, or finish material. The rim component 220 is formed byplacing a thin layer of a moldable polymeric material such as apolyester material into a first mold. The mold heats and preferablycompresses the polyester material and creates a rigid rim in the generalshape of the perimeter of the seat or back. The mold further forms aplurality of openings spaced around the rim component.

The rim component is then placed in a second mold. Fasteners 230, suchas Christmas tree fasteners include a one-way insert portion such asdistal member 232 in FIG. 5, that are inserted in the openings of therim. The term “one-way” insert portion means the fastener can be easilyinserted in one direction, but cannot be easily removed in the other,opposite direction.

Additional moldable material such as polyester material, preferably inthe form of a layer, is placed in the second mold on top of the rim. Themoldable material can include partially, or in its entirety, thepreviously described vertically lapped fibers or nonwoven batt thereof.The pad component 217 is formed and bonded to the rim component 220 withheat. The fasteners 230, can include a top flange component 236, aretrapped or secured/in-molded between the rim component and padcomponent. The second mold further trims or cuts the perimeter of thepad component. By making the rim component 220 separately from the padcomponent 217, the rim component can be made more rigid such that it cansupport the fasteners 230.

Next, the bonded rim and pad components 220, 217 are inserted into athird mold. A powder adhesive is added to the top of the pad componentand a fabric covering is placed over the top of the pad component. Themold heat cures the fabric 211 onto the pad component 217. The moldfurther forms the shape of the pad around the edge thereof, for exampleby forming a radius or curve to the edge. The mold can further formembossments resembling a plurality of inwardly extending or outwardlyextending geometric characters such as dimples, in the top of the padassembly. In one embodiment, the geometric characters are formed byusing pins.

After the pad assembly is removed from the third mold, the fabric 211 istrimmed and wrapped around the bottom of the assembly where it issecured with adhesive. The pad can be secured to an underlying supportmember by placing the support member in a die, which stamps or forms aplurality of openings shaped and dimensioned to receive the one-wayinsert portion of the fasteners. The pad assembly 200 is then secured tothe support member by inserting the fasteners into the openings with aone-way attachment and pressing the pad assembly and seat supporttogether.

Rather than the exemplary geometric characters, other markings, signageor indicia can be embossed into the chair seat and/or back, includingfor example and without limitation the name of a business, department orindividual, or other designs.

When forming a seat cushion from the previously described nonwoven battof vertically lapped fibers, a preferred method is as follows. The seatcushion can be formed by employing a modified thermoforming process inwhich a heated tool is used to compress and create select regions ofvarying strength and rigidity within the seat cushion. The tool servesto emboss or compress the fiber batt in only desired regions. Thetooling is configured such that it controls the areas at which embossingoccurs. Those regions of the batt which are not contacted by the heatedtool retain their cushioning characteristic.

As noted, the tool is heated. Although the particular temperature of thetool varies depending upon the specific materials in the batt, andprimarily with regard to the second fiber, an approximate temperaturerange for the tool is from about 150° F. to about 375° F. and preferablyabout 200° F. to about 325° F. It will be appreciated that if lowertemperatures are to be used for the heated tool, the holding times canbe increased to promote heat transfer from the tool to the batt andfibers therein. Generally, exemplary heating hold times are in the rangeof from about 60 seconds to about 90 seconds. However, it will beappreciated that the present invention includes the use of shorter orlonger hold times. Also, it is significant and preferred that thetool(s) or mold(s) themselves are heated to thereby heat their contents.Thus, it is preferred that at least one mold set utilize a directheating strategy, and most preferred that all molds or mold sets use adirect heating strategy. As will be appreciated, a direct heatingstrategy can be performed by using tool(s) with heating passages inwhich a heating fluid can pass. Alternately, electrically heated tool(s)could be used.

During application of the heated tool to the nonwoven batt of verticallylapped fibers, it is preferred to apply the tool with a compressiveforce, onto the batt. Generally, such pressures range from about 15 psito about 25 psi. Again, the present invention includes the use ofgreater or lesser pressures.

An exemplary embodiment process for forming a preferred embodiment seatcushion using vertically lapped fibers is depicted in FIGS. 15-18 asfollows. FIG. 15 illustrates a ring or retainer component 1220 formedfrom a tool assembly 1210. The tool assembly 1210 defines a moldingsurface 1212 which is preferably contoured according to the desiredshape of the seat to be produced. A collection of upwardly projectinglocator tabs 1214 extend around the perimeter of the molding surface1212 of the tool 1210. The tool 1210 can also include one or moreheating provisions 1216 such as electrical heating members oralternatively, channels for the passage of heating fluid. The ring 1220is preferably formed by placing one or more sections or pieces of amaterial to be heated and/or molded on the tool 1210, and specificallyon the molding surface 1212 and preferably adjacent to the locator tabs1214. Generally, three or four loose sections of material forming ring1220 are placed on the molding surface 1212 and alongside and around theperimeter of the molding surface 1212. A corresponding half of the toolassembly (not shown) is then placed over the ring components and inengagement with the tool 1210 and the resulting assembly is heated tothereby compress and thermally bond the material and form a unitaryrigid structure for the ring 1220. One or both of the mold halves suchas tool 1210 can include projections that form apertures 1222 in thering 1220.

FIG. 16 illustrates formation of an intermediate assembly of thepreferred seating cushion. The intermediate assembly is designated as1240 and is formed from placing a completed ring assembly 1220, aspreviously described, in another tool or die assembly 1230 andspecifically on a molding surface 1232 of the tool 1230. The tool 1230may include one or more heating provisions 1236. On top of the ring 1220placed on molding surface 1232 of the tool 1230, a layer of a moldablebatt or other material, preferably a PET thermoformable material, ispositioned. A corresponding top portion (not shown) of the moldingassembly 1230 is then lowered onto the layered assembly and the assemblyis heated and/or compressed to thereby thermoform the PET or other battmaterial. The heating and compression operation forms the collection ofmaterials into the desired shape, generally dictated by the contour ofthe molding surface 1232, and also bonds the layer of the moldable battonto the ring 1220 to thereby form the intermediate assembly 1240.

FIG. 17 illustrates completion of a final preferred seat member asdescribed herein using a layer of a vertically lapped fiber batt. Thecompleted seat member is designated as 1260 in FIG. 17 and also includesa layer of a decorative fabric disposed along its exterior. In formingseat member 1260, another tool or die assembly 1250 is shown whichdefines a molding surface 1252. The seat member 1260 is formed byplacing the intermediate assembly 1240 such as shown in FIG. 16, ontothe molding surface 1252 of the third molding assembly. Next, a layer ofthe vertically lapped fiber is then placed onto the intermediateassembly 1240, and a layer of a fabric or other decorative coveringmaterial is placed onto the relatively loose batt of the verticallylapped fiber layer. A corresponding half (not shown) of the tool or dieassembly 1250 is then placed thereon and engaged with the tool 1250 tocompress and partially heat the resulting assembly to thereby form thefinal seat member 1260 as shown in FIG. 17. Preferably, in using thethird tool or die assembly 1250, only the upper die member (not shown)is heated. Therefore, preferably, the lower or bottom portion of thetool or die assembly 1250 is not heated. This is to ensure that thevertically lapped fiber portion of the seat member 1260 is notexcessively heated which would otherwise reduce its cushioningcharacteristics. In FIG. 17, a pattern of dimples or recessions is notedas defined along the outer surface of the seat member 1260. Although nota requirement according to the present invention, such pattern can beformed by providing the molding surface in the upper tool or die memberof the assembly 1250 with a collection of outwardly extendingprojections in the desired pattern.

FIG. 18 illustrates the previously noted components of ring or retainer1220, the intermediate assembly 1240, and the final seat member 1260,alongside their respective molding assemblies, 1210, 1230 and 1250.

FIG. 19 is a schematic cross section of a preferred embodiment seatcushion 1300 utilizing a region of a vertically lapped fibrous batt. Theseat cushion 1300 corresponds to the seat member 1260 produced asdepicted in FIGS. 15-18. The cushion 1300 includes a ring component1320, an intermediate support and cushioning layer 1340, a region of avertically-lapped fibrous batt 1360, and a layer of a fabric or outercovering 1380 extending about the periphery of the layered assembly1320, 1340, and 1360, which as noted is preferably thermoformed.

It will be understood that the preferred embodiment seat cushions orother furniture components utilize a region of vertically lapped fibrousbatt, either alone or in combination with one or more regions ofcushioning layer(s).

FIG. 20 is a schematic cross section of a preferred embodiment arm pad1400 in accordance with the present invention. The arm pad 1400comprises a support or base member 1420, similar to the ring 1320, anintermediate support and cushioning layer 1440, and a region of avertically lapped fibrous batt 1460. The layered assembly is preferablycovered with an exterior cover 1480, such as a fabric or other layer.

FIG. 21 is another schematic cross section of another preferredembodiment arm pad 1500. The arm pad 1500 comprises a base member 1520,and a region of vertically lapped fibrous batt 1560 disposed thereon.The resulting assembly is covered with an outer layer 1580.

The arm pads 1400 and 1500 are preferably thermoformed and using thepreviously noted temperatures and pressures to form the arm pads in thedesired shapes.

FIGS. 22 to 46 are views of various seat assemblies and componentsthereof. Specifically, FIGS. 22 to 28 illustrate a preferred embodimentseat cushion 1300 having a collection of downwardly projectingengagement members 1310 along its underside and a patterned surfacealong an opposite side. Upon placement on a chair or other seating unit,the patterned surface faces upward and the engagement members contact,and preferably engage, the seating unit. Specifically, the seat assembly1300 as best shown in FIGS. 27 and 28 includes an intermediate layer1330, a ring or frame assembly 1340 extending around the periphery ofthe intermediate layer 1330, and a layer of an outer decorative material1350. The seat cushion 1300 includes a plurality of sides or outerperipheral regions such as regions 1360, 1362, 1364, and 1366 which,collectively, extend along the perimeter of the cushion 1300. In thepreferred seat assembly 1300, the intermediate layer 1330 is formed froma vertically lapped fiber as described herein. A plurality of optionaldimples 1320 may be formed along one or both faces of the seat cushion1300.

FIGS. 29 to 35 illustrate another preferred embodiment seat assembly1400. The seat assembly 1400 also includes a collection of downwardlyextending engagement members 1410 along its underside. Defined along itsopposite side is a patterned surface. As best shown in FIGS. 34 and 35,the preferred embodiment seat assembly 1400 includes an intermediatelayer 1430, a ring or frame assembly 1440 extending around the peripheryof the intermediate layer 1430, and an outer decorative layer 1450. Theseat cushion 1400 includes a plurality of sides or outer peripheralregions such as regions 1460, 1462, 1464, and 1466 which, collectively,extend along the perimeter of the cushion 1400. In the preferred seatassembly 1400, the intermediate layer 1430 is formed from a layer orregion of a vertically lapped fiber as described herein, and anotherlayer or region of a cushioning member. The layer or region ofcushioning member may be disposed adjacent the side of the assembly 1400facing upwards or downwards. The layer 1430 may define a plurality ofoptional dimples 1420.

FIGS. 36-42 illustrate a seat assembly 1500 prior to application of adecorative outer layer such as outer layers 1350 and 1450 shown in thepreviously described assemblies 1300 and 1400. Specifically, FIG. 36illustrates an intermediate layer 1530 having a ring or frame assemblywith a collection of downwardly extending projection members 1510. Theseat assembly 1500 includes a plurality of sides or outer regions suchas regions 1560, 1562, 1564, and 1566 which, collectively, extend alongthe perimeter of the assembly 1500. FIG. 41 clearly shows a ringassembly 1540 with a collection of engagement members 1510 extendingoutwardly therefrom. The ring 1540 extends about the periphery of layer1530. The intermediate layer 1530 preferably includes a region ofvertically lapped fiber as described herein. The upward facing surfaceof the assembly 1500 is preferably free of any pattern such as acollection of dimples or other depressions or projections.

FIGS. 43 and 44 illustrate a preferred arrangement of components thatare used to form a ring assembly 1600. Specifically, as shown in FIGS.43 and 44, a collection of four subcomponents or pieces of ring assemblyare arranged in a preferred pattern as shown in FIG. 43. Each of thepieces or members contain one or more apertures 1660. As shown in FIG.44, preferably, a slight overlap is provided between adjoining endregions of each ring component. FIGS. 43 and 44 depict the ring assembly1600 prior to molding. Upon molding the assembly, the overlap ensurescontact and engagement between adjacent pieces. Specifically, in FIG.44, overlap regions 1670, 1672, 1674, and 1676 are illustrated. In manyapplications it is more economical to form the ring assembly from acollection of smaller subcomponents rather than cutting or otherwiseforming, and then shipping or storing, an entire unitary assembly.

FIG. 45 illustrates the ring member 1650 after molding. The ring membernow features a much thinner profile due to compression of the assembly.FIG. 46 illustrates the components 1610, 1620, 1630, and 1640 formingthe ring assembly prior to molding. FIG. 47 also illustrates thecomponents prior to molding. FIG. 48 illustrates the collection of ringassembly components prior to compression and arrangement, illustratingtheir relatively large thickness prior to compression. The ring assemblycomponents can have a wide range of thicknesses, both prior to and aftermolding. In a preferred embodiment, the ring components exhibit athickness of from about 0.7 to about 1.5 cm, and preferably about 1.0cm. The ring after molding, preferably exhibits a thickness of fromabout 0.2 to about 0.6 cm, and preferably about 0.4 cm.

In alternative embodiments, the pad assembly is secured to the seatingstructure with adhesives, mechanical fasteners such as screws and thelike, or combinations thereof. In one embodiment, an anchor member, suchas a screw or the insert portion of the “Christmas tree” fastener isin-molded with the attachment portion extending from a rear or bottomside thereof. The attachment portion is received in mating holes (notshown) formed in the seating structure, for example with a snap-fit orby threading a nut thereon, so as to secure the pad to the seatingstructure.

Although the preferred embodiment seat cushions can be used inconjunction with nearly any mesh material forming a seat bottom, thepreferred seat cushions of the invention are particularly adapted to beused in association with the chairs having a mesh seat bottom describedand shown in one or more of the following patents or publications: U.S.Pat. Nos. 6,035,901; 6,702,390; 6,722,741; 6,726,286; 6,966,604; and2004/0189073; all of which are hereby incorporated by reference.

The preferred seat cushion embodiment using a nonwoven batt ofvertically lapped fibers can be utilized in other forms andapplications, and is not necessarily limited to use with the frame andengagement members described herein. For example, after suitableembossing and/or compression using the heated tools as described herein,the resulting cushions (formed from a nonwoven batt of vertically lappedfibers) can receive a frame member formed about the cushion by injectionmolding. Alternately, the preferred cushions can be attached to asubstrate or other seating surface by one or more mechanical fasteners.In addition, the cushions can be attached by welding heat, or adhesivestrategies. Sonic welding, spin weld fasteners, or heat staked fastenerscan be used.

The various seat cushions described herein can be used in a variety ofdifferent applications. For example, the cushions can be used in outdoorfurniture, stadium seating, heavy equipment seating, bus seating, trainseating, public transportation seating, motorcycle seating, recreationalvehicle seating, off-road vehicle seating, agricultural equipmentseating, and the like. Another application for which the seat cushionsdescribed herein can be used, is boating and related marine uses.

The invention has been described with reference to the preferredembodiments. Obviously, modifications and alterations will occur toothers upon a reading and understanding of this specification. Theinvention is intended to include all such modifications and alterations.

1. A furniture component comprising: a frame member; and a cushionmember disposed on the frame member, the cushion member having first andsecond oppositely directed faces; wherein the cushion member includes aregion of vertically lapped fibers, the region extending generallyacross a face of the cushion member, at least a majority of the fibersin the region extending in a direction generally transverse to a face ofthe cushion member.
 2. The furniture component of claim 1 wherein thefibers in the region of vertically lapped fibers has a size of from 0.9to 300 denier.
 3. The furniture component of claim 1 wherein the regionof vertically lapped fibers is used at a thickness so as to exhibit aweight of from about 100 g/m² to about 2000 g/m².
 4. The furniturecomponent of claim 1 wherein the region of vertically lapped fibersincludes from about 10% to about 100% of the total weight of fibers inthe cushion member.
 5. The furniture component of claim 1 wherein theregion of vertically lapped fibers comprises: from about 5% to about 95%of a first fiber, and from about 95% to about 5% of a second fiberhaving a melting point less than that of the first fiber.
 6. Thefurniture component of claim 5 wherein the first fiber has a size offrom about 0.9 denier to about 300 denier.
 7. The furniture component ofclaim 5 wherein the second fiber has a size of from about 2 denier toabout 15 denier.
 8. The furniture component of claim 5 wherein theinterior of the cushion member has a thickness of from about 0.5 cm toabout 7.6 cm.
 9. The furniture component of claim 1 wherein the framemember comprises: from about 30% to about 100% of a binder polymer; andfrom about 70% to about 0% of a matrix fiber.
 10. The furniturecomponent of claim 1 wherein the frame member is generally planar andhas a thickness of about 0.25 cm to about 0.025 cm.
 11. The furniturecomponent of claim 1 wherein the frame member includes at least oneengagement member extending therefrom.
 12. The furniture component ofclaim 11 wherein the at least one engagement member is formed from thesame material as the frame member.
 13. The furniture component of claim11 wherein the at least one engagement member is formed from a moldablepolymeric material selected from the group consisting of polyethylene,polypropylene, polystyrene, and combinations thereof.
 14. The furniturecomponent of claim 1 further comprising: a covering layer disposed onthe cushion member.
 15. The furniture component of claim 1 wherein thefurniture component is selected from the group consisting of seats, seatcushions, seat backs, arm pads, and combinations thereof.
 16. Thefurniture component of claim 1 wherein the frame member has a thicknessof from about 0.25 cm to about 0.025 cm.
 17. The furniture component ofclaim 1 wherein at least one of the first and second faces of thecushion member defines a plurality of inwardly or outwardly extendinggeometric characters.
 18. The furniture component of claim 1 wherein thecushion member also includes a second region of a cushioning material,disposed adjacent to the region of vertically lapped fibers.
 19. Aremovable seat cushion adapted for use with a chair having a mesh seatdefining a plurality of small apertures extending through the thicknessof the seat, the seat cushion comprising: a cushion member defining anupper surface and an oppositely directed bottom surface, the cushionmember including a region of a nonwoven mat of vertically lapped fibers;a frame component generally extending along at least one of (i) thebottom surface of the cushion member, and (ii) the outer periphery ofthe cushion member; and a plurality of downwardly extending engagementmembers affixed to the frame component and adapted to releasably engagethe mesh seat of the chair.
 20. The seat cushion of claim 19 wherein thefiber of the region of vertically lapped fibers has a size of from 0.9to 300 denier.
 21. The seat cushion of claim 19 wherein the region ofvertically lapped fibers comprises: from about 5% to about 95% of afirst fiber, and from about 95% to about 5% of a second fiber having amelting point less than that of the first fiber.
 22. The seat cushion ofclaim 19 wherein the frame member comprises: from about 30% to about100% of a binder polymer; and from about 70% to about 0% of a matrixfiber.
 23. The seat cushion of claim 19 further comprising: a coveringlayer disposed on the cushion member.
 24. The seat cushion of claim 19wherein the cushion member also includes a second region of a cushioningmaterial, disposed adjacent to the region of vertically lapped fibers.25. A method of forming a seat cushion having a region of verticallylapped fibers, the method comprising: forming a frame component byplacing a thin layer of a moldable polymeric material into a first mold,and heating to thereby form the frame; positioning the frame in a secondmold in conjunction with a plurality of fasteners adapted to be moldedto or otherwise affixed to the frame, and a layer of a nonwoven batt ofvertically lapped fibers, and heating the frame, fasteners, and layer tothereby form an intermediate assembly; and positioning the intermediateassembly into a third mold in conjunction with a layer of a coveringmaterial in position to cover a face of the intermediate assembly, andheating the intermediate assembly and covering material to thereby formthe seat cushion.
 26. The method of claim 25 wherein the first moldincludes a plurality of outwardly extending projections to thereby forma plurality of openings in the frame component.
 27. The method of claim26 wherein the fasteners, prior to molding in the second mold, are atleast partially extended through corresponding openings of the pluralityof openings formed in the frame component.
 28. The method of claim 25wherein prior to heating the intermediate assembly and coveringmaterial, an effective amount of an adhesive is disposed between theassembly and the covering material.
 29. The method of claim 25 whereinthe nonwoven batt of vertically lapped fibers contains a majority offibers extending in a direction approximately transverse to the plane ofthe batt.
 30. The method of claim 29 wherein of the transverselyextending fibers, at least 50% of their length extends in suchdirection.
 31. The method of claim 30 wherein of the transverselyextending fibers, at least 90% of their length extends in suchdirection.
 32. The method of claim 31 wherein of the transverselyextending fibers, at least 95% of their length extends in suchdirection.
 33. The method of claim 25 wherein the layer of nonwoven battof vertically lapped fibers is heated by heating the second mold to atemperature of from about 150° F. to about 375° F.
 34. The method ofclaim 25 wherein at least one of the first mold, the second mold, andthe third molds are heated to a temperature of from about 150° F. toabout 375° F.
 35. The method of claim 34 wherein all of the first,second, and third molds are heated to a temperature of from about 150°F. to about 375° F.